X-Ray & CT Scanning Archives - Industrial Inspection & Consulting

Industrial Inspection: Switch 2 X-ray & CT

When the pinnacle of INSPECTION and engineering collide

Industrial Inspection pushes the limits of electronics inspections by using digital X-ray imaging to provide the highest quality data on the market – like with the Nintendo Switch 2.

Why? Because flawless fit and build quality isn’t a guessing game. With our expertise every button cutout, every vent alignment, and every curve is built on cold, hard data.

HIGH RESOLUTION CT SCAN OF SWITCH 2

GAME PORT ACTION

We X-rayed the Nintendo Switch 2’s game card slot both with and without a cartridge inserted to analyze changes in the internal contact mechanisms. By comparing the two states, we can observe how the spring-loaded pins engage, check for any mechanical interference, and confirm how the system physically and electrically connects to the game card.

JOYCON CONNECTION

HIGH RESOLUTION ELECTRONICS INSPECTION

X-ray inspection of the Nintendo Switch 2’s internal electronics reveals generally high-quality solder joints, with consistent wetting and minimal voiding. However, we did observe some porosity — small gas pockets or voids — especially in the larger ground pads and under certain BGA components. These are common in high-density consumer electronics and usually fall within industry standards, but their presence is worth noting for anyone evaluating long-term reliability or thermal performance.

CT Scanning Aluminum Charged Air Cooler for Leaks

CT scanning was used to nondestructively identify leaks in the seal area of this aluminum charged air cooler. A high exposure helical scan was used to capture a single, high resolution scan of the oblong assembly.

Helical scanning works by continuously rotating and raising the object with the part manipulator, creating a spiral dataset. The benefit of helix scans is that resolution is limited to the object’s greatest width, rather than it’s length. Additionally, CT artifacts like beam hardening are dissipated throughout the sample rather than concentrated in a localized, circular zone. Some drawbacks to helical scans are exceptionally large files (this was around 70gb), and spiral artifacts.

CT Scanning Fuel Injectors for Injector Angles

CT Scanning Fuel Injectors

Over the years we’ve been asked to participate in many fuel injector studies because their features are so small and difficult to characterize. CT is a great solution, providing water tight, high resolution, exportable data for visual and dimensional analysis of critical features.

Injector angles matter because they directly affect how efficiently fuel mixes with air inside an engine’s combustion chamber. Ensuring design criteria is met improves combustion, power output, fuel economy, and emissions.

CT Scanning Steel Microfluid Assemblies for Cracks & Profiles

CT SCANNING MICROFLUID ASSEMBLIES

CT scanning is used to inspect stainless steel micro connectors and valves for internal weld defects and dimensional accuracy. It reveals voids, cracks, or misaligned welds that aren’t visible from the outside, while also confirming that tight tolerances are met. The process is non-destructive and ideal for quality control in precision manufacturing. Traditional methods require sectioning samples for internal evaluations, which could damage or eliminate critical areas of interest.

Crack in micro-weld

CT scanning revealed the linear, cracklike indication in the weld below, which was undetectable by visual inspection and dye penetrant. The scan provided exact location, length, and depth, allowing for targeted evaluation of the weld quality and potential failure risk. Early detection like this is critical in high-precision or pressure-sensitive applications, where even small defects can compromise performance and mission integrity.

Measuring Internal Profiles

Micro-CT scanning is effective for measuring intentional surface roughness in steel microfluidic components because it captures high-resolution, water-tight, internal and external surface data. This allows engineers to evaluate surface conditions that influence flow behavior, such as turbulence or adhesion, within tiny channels or chambers. Unlike tactile or optical profilers, micro-CT can measure roughness on complex, internal geometries where direct non-destructive access is impossible, ensuring the intended surface characteristics are consistently produced and maintained throughout the part and its production.

IIC Launches X-RAY Authority

Chosen by the biggest names and serving a global clientele, we are the authority in characterizing and authenticating collectibles using non-destructive X-ray technology.

We’ve created X-ray Authority for better brand recognition and to solidify ourselves as the authoriy in collectibles authentications.

Inspecting Microfluidic Mixers

Industrial CT scanning is a powerful tool for inspecting microfluidic mixers, especially in industries where performance and reliability are critical such as medical diagnostics, pharmaceuticals, biotechnology, and chemical processing. These mixers often feature complex internal channels and structures that are impossible to evaluate with traditional inspection methods without cutting or destroying the part.

CT scanning provides a fully non-destructive way to see inside a microfluidic device and verify that it was manufactured correctly. It could even remain in its sealed packaging.

For example, it can detect internal blockages, trapped air bubbles, or incomplete bonding between layers, all of which can compromise fluid flow or lead to device failure in the field.

In addition to assembly inspection, CT scanning is used for high-precision dimensional analysis. It allows inspectors to measure internal features like channel widths, wall thickness, and GD&T like flatness and concentricity with micron-level accuracy. This is especially important in devices where small variations can affect flow behavior, mixing efficiency, or the timing of chemical reactions.

CT Scanning 3D Printed Steel Tooling for Leak Paths

One of our clients had issues with undetected internal leak paths within complex 3D printed steel tooling, compromising tool integrity and performance. Traditional inspection methods failed to reveal subsurface defects, prompting the use of industrial computed tomography scanning.

The high-resolution CT scans enabled non-destructive, full-volume analysis of the tooling, revealing internal porosity, profile deviations, and wear from water pitting. By visualizing and precisely locating these hidden defects, engineers have a better understanding for repair and corrective actions to mitigate future leakage risks. This application of CT scanning significantly improves quality assurance, reducing failure rates and increasing tool reliability.

This tooling and imaging is shared with permission by Grand Traverse Plastics.

Re-working Defects using CT Scan Data

REDUCING SCRAP BY RE-WORKING DEFECTIVE PRODUCTS

Inspection requirements and services are often considered “non-value added” because they cost money and could cause delays if the products do not meet specifications.

But, what if inspection services can be Value Saving?

Some parts we inspect are safety and mission critical. Other times, only a handful of parts are available and to produce more would require significant tooling and development costs. These parts could take months and many thousands of dollars to produce. If inherent, latent defects are causing significant scrap rates, we offer a way to accurately define the exact location of each defect within a part. By physically pinpointing exact defect locations and depths, we assist manufacturers in their re-work operations which can significantly reduce wasted material, cash, and production timelines.

Step 1: CT Scan the Product

The first step in this process is to collect CT scan data of the part. The CT data is then aligned to a CAD model. The origin and coordinate system of this CAD model is critical for the next steps. Once the CT scans are aligned to CAD our team of ASNT / NAS410 radiography specialists review the data and notate any rejectable indications. Volume Graphics indication points produce XYZ coordinates relative to the coordinate system of the project scene and coordinate system. We then export these indication coordinate points into a separate file.

Casting defects are particularly important if they are in high-stress zones, or near machined surfaces. We can determine if these defects are in these zones, and even modify CAD for boundary acceptability tolerancing. For example, the manufacturer may find defects acceptable up to .5mm from a machined surface. We can offset CAD surfaces by .5mm for an objective indicator of rejectability.

Step 2: LASER SCAN THE PART

The second step of this process is to laser scan the part. Once data is captured we align the scan to the same CAD model used in Step 1. Then, we import the indication coordinate points into PolyWorks.

Step 3: PROBE THE DEFECT

The third step of the process is to locate the indication coordinate points using the the probe of our laser scanner. Once the probe is within an allowable distance of the actual indication, the zone turns green.

Step 4: MARK THE DEFECT

Once the probe is within the acceptable zone of the indication, the technician uses their other hand to physically mark the indication defect on the part with a marker or paint pen. Then, manufacturers can machine or drill out the location and weld the geometry back for a defect free product.

Goldin Auctions & IIC team up for Collectibles Authentications

IIC provides Letter of Authentication to Goldin Auctions

Pokémon’s Chinese-language Base Set release is considered one of the rarest language localizations associated with the inaugural expansion. Looking through the lens of the most coveted card in the issue, Charizard’s 1st Edition Rare Holofoil entry, PSA has validated just 192 copies of the Chinese variation, as compared to nearly 14,000 Japanese-language copies (for which no “1st Edition” designation was given), more than 4,700 English-language examples, more than 2,000 German-language specimens, and more than 330 Spanish-language copies. The box’s exterior reflects minor, routine wear from handling and storage and remains securely sealed within the manufacturer’s cellophane wrapping.

This seldom-encountered booster box comes with a LOA from Industrial Inspection & Consulting LLC. IIC reviewed this specimen for Goldin to verify authenticity and confirm it has not been tampered with. Goldin has no knowledge of the contents or potential card identities. Goldin is proud to take these extra measures to ensure that Pokémon collectors receive a properly reviewed, unadulterated product.

COLLECTIBLES NEWS & UPDATES

Evaluating Pharmaceutical Medications and Pills using Industrial CT Scanning

INDUSTRIAL CT SCANNING FOR PHARMACEUTICAL EVALUATION

Industrial CT Scanning is used in the pharmaceutical industry to evaluate pills, tablets, and packaging to quantify characteristics like ingredient homogeneity, coating thickness, and drug release.

This case study highlights three common OTC medications to demonstrate how CT scanning can benefit pharmaceutical manufacturers.

Tylenol Rapid Release - RELEASE MECHANISM

CT scanning helps to detect defects such as air pockets, cracks, or uneven coating. These defects could affect the pill’s effectiveness, so identifying them during production is critical. The below image shows a crack within the outer coating and shell.

The Rapid Release shell is a deliberately porous structure designed to increase solubility and the speed of release of the drug.

ADVIL LIQUI-GEL - SHELL THICKNESS

Advil Liqui-Gels contain a liquid form of ibuprofen, and the shell needs to be thick enough to maintain the integrity of the capsule. The shell serves as a barrier that keeps the liquid stable and prevents it from leaking or evaporating before the capsule is ingested. Additionally, the shell thickness helps regulate the rate of dissolution, which is crucial for ensuring the drug is released in a predictable manner.

ALLEGRA 180mg - HOMOGENEITY

Homogeneity refers to the uniform distribution of the active pharmaceutical ingredient (API) and excipients (inactive ingredients) throughout the encapsulated formulation. CT scanning helps evaluate products to ensure that each dose of medication contains a consistent amount of medication, meets granulation and compaction requirements.

Category: X-Ray & CT Scanning